A cardboard casket includes a top piece and a bottom piece. The top piece is formed by making a single press die cut in a reinforced core cardboard panel, including cutting the reinforced core cardboard panel to form the top piece and forming seams in the top piece. The bottom piece is formed by making another single press die cut in another reinforced core cardboard panel, including cutting the other reinforced core cardboard panel to form the bottom piece and forming seams in the bottom piece. Cutting the top and bottom pieces includes cutting through a first layer, a reinforced core, and a second layer of the reinforced core cardboard panels. forming seams in the top and bottom pieces includes deforming the first layer in the seams, deforming a majority of the reinforced core in the seams, and leaving the second layer in the seam uncut.
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1. A method of forming pieces of a cardboard casket, the method comprising:
forming a top piece of the cardboard casket, wherein forming the top piece comprises making a first single press die cut in a first reinforced core cardboard panel, wherein making the first single cut die press includes cutting the first reinforced core cardboard panel to form the top piece and forming seams in the top piece;
forming the bottom piece of the cardboard casket, wherein forming the bottom piece comprises making a second single press die cut in a second reinforced core cardboard panel, wherein making the second single cut die press includes cutting the second reinforced core cardboard panel to form the bottom piece and forming seams in the bottom piece; and
printing, on an outer surface of the top piece, one or more of text, graphics, or a background image;
wherein each of the first and second reinforced core cardboard panels comprises a first layer, a second layer, and a reinforced core located between the first and second layers;
wherein cutting each of the top and bottom pieces includes cutting through the first layer, the reinforced core, and the second layer of one of the first and second reinforced core cardboard panels; and
wherein forming seams in each of the top and bottom pieces includes deforming the first layer in the seams, deforming a majority of the reinforced core in the seams, and leaving the second layer in the seam uncut.
2. The method of
for printing, receiving a request for customized printing on the top piece.
3. The method of
4. The method of
5. The method of
6. The method of
placing adhesive on an outer surface of the second layer of a tab of the top piece.
7. The method of
folding the top piece along the seams of the top piece such that the adhesive on the tab adheres to the first layer of a side panel of the top piece.
8. The method of
9. The method of
10. The method of
11. The method of
placing the reinforcement piece against the side panel of the bottom piece with the pair of handle holes in the reinforcement piece aligned with the pairs of handle holes in the side panel.
12. The method of
feeding ends of a handle through the aligned pair of handle holes in the reinforcement pieces and the pair of handle holes in the side panels; and
tying a knot in each of the ends of the handle to prevent the ends of the handle from being pulled back through the pair of handle holes in the reinforcement pieces and the pair of handle holes in the side panels.
13. The method of
14. The method of
15. The method of
folding the bottom piece along the seam between the main panel and the side panel to form an angle between the main panel and the side panel;
folding the bottom piece along the pair of seams between the side panel and the ledge panel such that the first layer of the side panel is substantially parallel to the first layer of the ledge panel; and
adhering the first layer of the side panel to the first layer of the ledge panel.
16. The method of
17. The method of
folding the bottom piece along the seam between the main panel and the end panel to form an angle between the main panel and the end panel; and
adhering the end panel to two tabs of the bottom piece.
18. The method of
adhering an extension piece to the two tabs of the bottom piece above the end panel.
19. The method of
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This application claims the benefit of U.S. Provisional Application No. 62/181,098, filed Jun. 17, 2015, the disclosure of which is incorporated by reference herein in its entirety.
Human remains are frequently contained in caskets prior to burial, entombment, or cremation. Traditional materials for caskets include various types of wood, such as oak, pine, and bamboo, various metal materials, such as steel and aluminum, and other structural materials, such as fiberglass or other composite materials. Traditional materials ensure that structural integrity of the casket while providing a dignified container for human remains. One benefit to these materials is that caskets can be used during memorial services and funerals to commemorate the dead in a dignified manner.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In one embodiment, a method of forming pieces of a cardboard casket includes forming a top piece of a cardboard casket, forming a bottom piece of the cardboard casket, and printing, on an outer surface of the second layer of the top piece, one or more of text, graphics, or a background image. Forming the top piece includes making a first single press die cut in a first reinforced core cardboard panel. Making the first single cut die press includes cutting the first reinforced core cardboard panel to form the top piece and forming seams in the top piece. Forming the bottom piece includes making a second single press die cut in a second reinforced core cardboard panel. Making the second single cut die press includes cutting the second reinforced core cardboard panel to form the bottom piece and forming seams in the bottom piece. Each of the first and second reinforced core cardboard panels includes a first layer, a second layer, and a reinforced core located between the first and second layers. Cutting each of the top and bottom pieces includes cutting through the first layer, the reinforced core, and the second layer of one of the first and second reinforced core cardboard panels. Forming seams in each of the top and bottom pieces includes deforming the first layer in the seams, deforming a majority of the reinforced core in the seams, and leaving the second layer in the seam uncut.
In one example, the method further includes receiving a request for customized printing on the top piece. In another example, the request for customized printing on the top piece includes one or more of an image or text for printing on the top piece.
In one example, the reinforced core of each of the first and second reinforced core cardboard panels includes cells of a geometric shape. In another example, the geometric shape of the cells is a hexagon.
In one example, forming the top piece further includes placing adhesive on an outer surface of the second layer of a tab of the top panel. In another example, forming the top piece further includes folding the top piece along the seams of the top piece such that the adhesive on the tab adheres to the first layer of a side panel of the top piece.
In one example, making the first single cut die press further includes cutting a reinforcement piece from the first reinforced core cardboard panel. In another example, making the first single cut die press further includes cutting a pair of handle holes in the reinforcement piece. In another example, making the second single cut die press includes cutting a pair of handle holes in a side panel of the bottom piece. In another example, placing the reinforcement piece against the side panel of the bottom piece with the pair of handle holes in the reinforcement piece aligned with the pairs of handle holes in the side panel. In another example, the method further includes feeding ends of a handle through the aligned pair of handle holes in the reinforcement pieces and the pair of handle holes in the side panels and tying a knot in each of the ends of the handle to prevent the ends of the handle from being pulled back through the pair of handle holes in the reinforcement pieces and the pair of handle holes in the side panels.
In one example, an outer surface of the second layer of the bottom piece is printed before making the second single press die cut.
In one example, the seams in the bottom piece include a seam between a main panel and a side panel and a pair of seams between the side panel and a ledge panel. In another example, forming the bottom piece further includes folding the bottom piece along the seam between the main panel and the side panel to form an angle between the main panel and the side panel, folding the bottom piece along the pair of seams between the side panel and the ledge panel such that the first layer of the side panel is substantially parallel to the first layer of the ledge panel, and adhering the first layer of the side panel to the first layer of the ledge panel.
In one example, the seams in the bottom piece include a seam between a main panel and an end panel. In another example, forming the bottom piece further includes folding the bottom piece along the seam between the main panel and the end panel to form an angle between the main panel and the end panel, and adhering the end panel to two tabs of the bottom piece. In another example, the method further includes adhering an extension piece to the two tabs of the bottom piece above the end piece. In another example, making the first single cut die press further includes cutting the extension piece from the first reinforced core cardboard panel.
In another embodiment, a cardboard casket includes a bottom piece and a top piece. The bottom piece and the top piece are produced from a method that includes forming the top piece by making a first single press die cut in a first reinforced core cardboard panel and forming the bottom piece by making a second single press die cut in a second reinforced core cardboard panel. Making the first single cut die press includes cutting the first reinforced core cardboard panel to form the top piece and forming seams in the top piece. Making the second single cut die press includes cutting the second reinforced core cardboard panel to form the bottom piece and forming seams in the bottom piece. Each of the first and second reinforced core cardboard panels includes a first layer, a second layer, and a reinforced core located between the first and second layers. Cutting each of the top and bottom pieces includes cutting through the first layer, the reinforced core, and the second layer of one of the first and second reinforced core cardboard panels. Forming seams in each of the top and bottom pieces includes deforming the first layer in the seams, deforming a majority of the reinforced core in the seams, and leaving the second layer in the seam uncut.
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
Cardboard is an alternative material used to make caskets. Cardboard caskets have a number of advantages over traditional casket materials. One advantage is that cardboard materials are typically less expensive than traditional materials, such as wood, metal, or composite materials. The lower cost of cardboard materials reduces the overall cost of cardboard caskets compared to traditional caskets. Another advantage is that cardboard materials typically weigh less than traditional materials. The lower weight of cardboard materials reduces the overall weight of cardboard caskets compared to traditional caskets. Another advantage of cardboard caskets is that they are customizable. Text and graphics (e.g., pictures or other images) can be printed on a cardboard casket to customize them for the particular individual whose remains it holds. Customization of cardboard caskets is discussed in greater detail below.
Other benefits of cardboard caskets relate to the different ways in which they can be used. In the case of human remains that are to be cremated, the remains can be left in the cardboard casket during the cremation process. This allows a cardboard casket to be used to hold human remains prior to cremation (e.g., during a memorial service or funeral) and then the cremation process can be performed without removing the human remains from the cardboard casket. In one example, the cost of the cardboard casket is less than the cost of renting a traditional casket for use during a memorial service or funeral. In the case of human remains that are to be buried or entombed, cardboard caskets have the benefit of being biodegradable. Because cardboard caskets are biodegradable, they are less harmful for the environment and decompose naturally as the human remains inside them decompose. Cardboard caskets offer additional benefits beyond those mentioned here.
While cardboard caskets offer a number of benefits, many consumers perceive a deficiency in the structural integrity of cardboard caskets. Consumers are less likely to buy cardboard caskets if they perceive cardboard caskets to be structurally deficient. As described in greater detail below, reinforced core cardboard can provide the structural integrity required for cardboard caskets. In addition, a single-press die cut process can cut and create seams in reinforced core cardboard that allow the reinforced core cardboard to be folded into the proper shape of either a bottom piece or a top piece of a cardboard casket. Various embodiments of reinforced core cardboard caskets and pieces thereof are described herein.
One embodiment of reinforced core cardboard usable in the embodiments of cardboard caskets is depicted in
The panel 20 also includes a reinforced core 26 located between the first and second layers 22 and 24. The reinforced core 26 is configured to withstand a particular pressure without deforming. In one example, the core 26 is configured to withstand a particular pressure in a range from about 11 pounds per square inch (psi) to about 60 psi. In one embodiment, as depicted in
The panel 20 can have particular dimensions. In some embodiments, the thickness of the panel 20 (i.e., the distance from the outer surface of the first layer 20 to the outer surface of the second layer 22) is in a range from about 0.375 inches to about 4.0 inches. In another embodiment, the panel 20 is formed with a particular length and a particular width. In some examples, the length is less than or equal to about 120 inches. In other examples, the width is less than or equal to about 60 inches. In yet other examples, the panel 20 is sold at a standard length of about 96 inches (i.e., 8 feet) and a standard width of about 48 inches (i.e., 4 feet).
Various pieces of cardboard coffins can be formed from panels of reinforced core cardboard, such as the panel 20 depicted in
The top piece 100 has a number of cuts and seams that are formed by a die cutting process, as discussed in more detail with respect to
As seen in the cross-sectional side view in
An embodiment of a single press die cut to create the top piece 100 is depicted in the cross-sectional views in
In
In one embodiment, after the top piece 100 is die cut, the outer surface of the second layer 104 is prepared as depicted in
In one embodiment, the text, graphics, and/or background image on the outer surface of the second layer 104 of the top piece 100 are customized for the deceased. For example, a background image can be related to an interest of the deceased, the text 136 includes a name of the deceased, and the graphics 138 includes an image of the deceased. In one embodiment, customers are able to select the background image from pre-approved images and customers provide text and/or images for the text 136 and graphics 138. It may be advantageous to provide pre-approved images for selection by customers for the background image due to the resolution required for the image on a large surface, such as the top piece 100 of a cardboard casket. In one embodiment, a living person may pre-order and customize a cardboard casket while alive and the cardboard casket can be printed following the person's death. In other embodiments, surviving family or friends may order and customize a cardboard casket after a death.
In addition to printing on the outer surface of the second layer 104 of the top piece 100 after the top piece 100 is die cut, adhesive 140 can be added to portions of the second layer 104. In the embodiment depicted in
The bottom piece 200 has a number of cuts and seams that are formed by a die cutting process, similar to the die cutting process discussed above with respect to
In one embodiment, the bottom piece 200 is formed from a reinforced core cardboard panel using a single press die cut, similar to the single press die cut of the top piece 100 described above with respect to
The outer surface of the second layer 204 of the bottom piece 200 can also have printing. In one example, the outer surface of the second layer 204 may be printed before the bottom piece 200 is die cut. For example, the outer surface of the second layer 204 may be a single color (e.g., black) or have a basic pattern (e.g., wood grain) before it is die cut. A single color or a basic pattern may be usable with many of the customizable images on the top piece 100 such that the bottom pieces do not need customized printing. After the bottom piece 200 is die cut, the pre-printed outer surface of the second layer 204 will be ready for assembly. In another example, the outer surface of the second layer 204 may be printed after the bottom piece 200 is die cut. Printing the bottom piece 200 after die cutting may allow for customization with text, graphics, background images, and like, similar to the customization of the top piece 100 described above. In one embodiment, after the bottom piece 200 is printed and/or the adhesive 228 and 230 is adhered to the bottom piece 200, the bottom piece 200 can be shipped to a customer, such as a funeral home or mortuary, in the flat condition depicted in
The tabs 218 are also folded in along the seams 216 to form an angle between the tabs 218 and the side panels 210. In one example, the angle between the tabs 218 and the side panels 210 is about 90°. At the point shown in
Each of the reinforcement pieces 234 has a pair of handle holes 236. In one embodiment, the handle holes 236 have a size corresponding to a size of the handle holes 224 in the side panels 210. In another embodiment, each pair of handle holes 236 is spaced apart at a distance corresponding to a spacing of the handle holes 224 in the side panels 210. In another embodiment, each of the reinforcement pieces 234 is placed against the side panel 210 such that the pairs of handle holes 236 are aligned with the pairs of handle holes 224 in the side panels 210.
In the embodiment shown in
After the top piece 302 and the bottom piece 304 are formed, human remains can be placed into the bottom piece 304. In some embodiments, the weight of the human remains may exceed an upper weight limit of the bottom piece 304. In those cases, a tray (not shown) can be added to the inside of the bottom piece 304 prior to the human remains being placed in the bottom piece 304. The tray can add structural integrity to the bottom piece 304 and increase the weight holding capacity of the bottom piece 304.
After human remains are placed into the bottom piece 304, the top piece 302 can be placed over the bottom piece 304, as shown in
After the top piece 302 is fastened to the bottom piece 304, the cardboard casket 300 is suitable for use in a memorial service or funeral, in burial or entombment, or in cremation. In one embodiment, the materials used in the cardboard casket 300 (e.g., reinforced core cardboard, adhesive, handles, etc.) are biodegradable materials that will degrade over time after burial. In one embodiment, the materials used in the cardboard casket 300 are combustible such that the entire cardboard casket 300 with the human remains inside can be used in a cremation process. In another embodiment, most of the materials used in the cardboard casket 300 are combustible and the non-combustible materials are removable from the cardboard casket 300 such that the combustible portions of the cardboard casket 300 with the human remains inside can be used in a cremation process.
Having a gap 318 between the top piece 312 and the bottom piece 314 of the cardboard casket 310 is typically not an acceptable configuration, particularly when the cardboard casket 310 is used to hold human remains.
It should be noted that for purposes of this disclosure, terminology such as “upper,” “lower,” “vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,” “front,” “rear,” etc., should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings.
The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure, as claimed.
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